Method of forming elastomeric laminates having targeted elastic properties for use in personal care articles

ABSTRACT

A method of forming an elastomeric laminate having targeted elastic properties for use in personal care articles is disclosed. In particular embodiments, the method comprises providing first and second nonwoven webs; providing a core layer of elastomeric material under tension; sandwiching the core layer between the first and second nonwoven webs; bonding the core layer to at least one of the first and second nonwoven webs; providing an elastomeric film ribbon web under tension; sandwiching the elastomeric film ribbon web between the first and second nonwoven webs; and fusing the elastomeric film ribbon web to the first and second nonwoven webs. In particular embodiments, the core layer of elastomeric material is an elastomeric film web core layer. In particular embodiments, the elastomeric film ribbon web, the core layer, or both is/are bonded to the first and second nonwoven webs solely by fusing, without the use of adhesive.

PRIORITY

This application is a divisional of application Ser. No. 12/981,167,entitled Method of Forming Elastomeric Laminates Having Targeted ElasticProperties for Use in Personal Care Articles, and filed in the U.S.Patent and Trademark Office on Dec. 29, 2010. The entirety of the priorapplication is hereby incorporated by reference in this application.

BACKGROUND

Disposable personal care articles are common in society, includingdiapers, training pants, enuresis pants, adult incontinence garments,feminine hygiene articles, surgical garments, protective wear, and thelike. Frequently, such articles are constructed of polymeric substrates,including, for example, polyolefin films and polyolefin nonwovens likespunbond materials or carded web materials. It is commonly desirable toprovide such articles with elastic properties, such as via the use ofelastic strands or elastic films. It is also commonly desirable toprovide such articles with targeted or localized elastic properties forspecific functionality. For example, it is frequently desirable toprovide elasticization at one of more edges of certain articles, such asat the leg and waist opening of garments, at the crotch edge ofmenstrual or incontinence pads, or at the wrist or neck openings ofdisposable garments, such as surgical or safety gowns or coats. Theconventional approach to providing such elasticization has been toadhesively fix rubber-like strands of elastomeric material to thepolymeric substrate. Upon release of the tensioning force, the elasticstrands gather the substrate, providing the desired functionalproperties, such as, for example, providing a snug fit around the leg orwaist opening of a disposable garment. This conventional approach toelasticization requires the use of adhesive to bond the elastic strandsto the substrate, and to hold them in place when under tension. Suchadhesive adds cost and process complexity to the manufacture of sucharticles. In addition, there is restricted ability to recycle waste andscrap from such a manufacturing process because such waste or scrapcontains a mix of components—polyolefin substrates, rubber-like elasticthreads, and adhesive. Therefore, what is needed is an improved methodof providing targeted or localized elastic properties in disposablepersonal care articles without the need for adhesive.

SUMMARY OF PARTICULAR EMBODIMENTS OF THE INVENTION

In one aspect, the present invention relates to a method of forming anelastomeric laminate having targeted elastic properties for use inpersonal care articles. The method defines a machine direction and across-machine direction. In particular embodiments, the method comprisesproviding first and second nonwoven webs, each defining across-direction width; providing a core layer of elastomeric materialunder tension, the core layer having a cross-direction width at least75% that of the width of at least one of the first and second nonwovenwebs; sandwiching the core layer of elastomeric material between thefirst and second nonwoven webs; bonding the core layer of elastomericmaterial to at least one of the first and second nonwoven webs;providing an elastomeric film ribbon web under tension; sandwiching theelastomeric film ribbon web between the first and second nonwoven webs;and bonding the elastomeric film ribbon web to the first and secondnonwoven webs by fusing the elastomeric film ribbon web to the first andsecond nonwoven webs. In particular embodiments, the elastomeric filmribbon web is bonded to the first and second nonwoven webs solely byfusing, without the use of adhesive. In particular embodiments, the corelayer of elastomeric material is an elastomeric film web core layer. Inparticular embodiments, bonding the core layer of elastomeric materialto at least one of the first and second nonwoven webs comprises fusingthe elastomeric film web core layer to the at least one of the first andsecond nonwoven webs. In particular embodiments, the elastomeric filmweb core layer is bonded to at least one of the first and secondnonwoven webs solely by fusing, without the use of adhesive.

In another aspect, the present invention relates to a method ofmanufacturing a personal care garment, the garment comprising anelastomeric laminate having targeted elastic properties. The methoddefines a machine direction and cross-machine direction. In particularembodiments, the method comprises providing first and second nonwovenwebs, each defining a cross-direction width; providing a core layer ofelastomeric material under tension, the core layer having across-direction width at least 75% that of the width of at least one ofthe first and second nonwoven webs; sandwiching the core layer ofelastomeric material between the first and second nonwoven webs; bondingthe core layer of elastomeric material to at least one of the first andsecond nonwoven webs; providing an elastomeric film ribbon web undertension; sandwiching the elastomeric film ribbon web between the firstand second nonwoven webs; and bonding the elastomeric film ribbon web tothe first and second nonwoven webs by fusing the elastomeric film ribbonweb to the first and second nonwoven webs. In particular embodiments,the personal care garment when donned defines a waist opening and twoleg openings, and the elastomeric film ribbon web is positioned adjacentthe waist opening, one or both of the two leg openings, or both thewaist opening and the leg openings.

Various embodiments of the present invention can in particular instancesprovide efficient techniques for manufacturing elastomeric laminates foruse in constructing personal care articles. In particular embodiments,such techniques eliminate the use of adhesive in the laminating stage ofthe process, thereby reducing material and potentially capital equipmentcost. Furthermore, the ease with which scrap materials may be recycledmay, in certain embodiments, be improved.

Definitions

Within the context of this specification, each term or phrase below willinclude the following meaning or meanings. Additional terms are definedelsewhere in the specification.

“Attached” refers to the joining, adhering, bonding, connecting, or thelike, of two elements. Two elements will be considered to be attachedtogether when they are attached directly to one another or indirectly toone another, such as when each is directly attached to intermediateelements.

“Bonded” refers to the joining, adhering, connecting, attaching, or thelike, of two elements. Two elements will be considered to be bondedtogether when they are bonded directly to one another or indirectly toone another, such as when each is directly bonded to intermediateelements.

“Comprising” is inclusive or open-ended and does not exclude additional,unrecited elements or method steps.

“Disposable” refers to articles which are designed to be discarded aftera limited use rather than being laundered or otherwise restored forreuse.

“Disposed,” “disposed on,” and variations thereof are intended to meanthat one element can be integral with another element, or that oneelement can be a separate structure bonded to or placed with or placednear another element.

“Elastic,” “elasticized” and “elasticity” mean that property of amaterial or composite by virtue of which it tends to recover itsoriginal size and shape after removal of a force causing a deformation.

“Elastomeric” refers to a material or composite which can be elongatedby at least percent of its relaxed length and which will recover, uponrelease of the applied force, at least 20 percent of its elongation. Itis generally preferred that the elastomeric material or composite becapable of being elongated by at least 100 percent, more preferably byat least 200 percent, of its relaxed length and recover, upon release ofan applied force, at least 50 percent of its elongation.

“Fusing” and its derivatives mean to unite two materials by at leastpartially thermally melting one or both of them. Two materials will beconsidered to be fused together when they are fused directly to oneanother or indirectly to one another, such as when each is directlyfused to intermediate materials.

“Integral” is used to refer to various portions of a single unitaryelement rather than separate structures bonded to or placed with orplaced near one another.

“Layer” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

These terms may be defined with additional language in the remainingportions of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 representatively illustrates a perspective view of one embodimentof an elastomeric laminate manufacturing process incorporatingprinciples of the present invention.

FIG. 2 representatively illustrates a perspective view of an alternativeembodiment of an elastomeric laminate manufacturing processincorporating principles of the present invention.

FIG. 3 representatively illustrates a perspective view of anotheralternative embodiment of an elastomeric laminate manufacturing processincorporating principles of the present invention.

FIG. 4 representatively illustrates a perspective view of yet anotheralternative embodiment of an elastomeric laminate manufacturing processincorporating principles of the present invention.

FIG. 5 representatively illustrates a perspective view of one embodimentof a garment manufacturing process incorporating principles of thepresent invention.

FIG. 6 representatively illustrates a perspective view of an alternativeembodiment of a garment manufacturing process incorporating principlesof the present invention.

FIG. 7 representatively illustrates a perspective view of anotheralternative embodiment of a garment manufacturing process incorporatingprinciples of the present invention.

FIG. 8 representatively illustrates a perspective view of yet anotheralternative embodiment of a garment manufacturing process incorporatingprinciples of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Reference to FIGS. 1-8 shall be made in describing various exampleswhich incorporate certain principles of the invention. It should benoted that the embodiments depicted in FIGS. 1-8 are merelyrepresentative examples of the invention. Although for illustrativepurposes certain features of the present invention shall be describedand illustrated with respect to a “cross-direction” garmentmanufacturing process, the various aspects and embodiments of thepresent invention are suitable for use with both “machine-direction” and“cross-machine-direction” processes, and include processes for makingsuch garments as disposable diapers, disposable swim pants, disposabletraining pants, disposable enuresis garments, feminine care products,surgical garments, and the like.

In one aspect, the present invention pertains to a method of forming anelastomeric laminate having targeted elastic properties for use inpersonal care articles. Referring to FIGS. 1-4, the method 10 defines amachine direction 20 and a cross-machine direction 21. The methodincludes providing a first nonwoven web 1 defining a cross-directionwidth 3, and a second nonwoven web 2 defining a cross-direction width 4.The method further comprises providing a core layer of elastomericmaterial 5 under tension. The core layer defines a width 6. The corelayer could be a series of elastomeric strands; in such a case the width6 is the distance in the cross-machine direction 21 measured between theouter edges of the two outermost strands. Preferably, the core layer 5is an elastomeric film web core layer 5 a. In particular embodiments,the core layer 5 has a cross-direction width 6 at least 75%, moreparticularly at least 90%, and still more particularly approximately100% that of at least one of the width 3 of the first nonwoven web 1 andthe width 4 of the second nonwoven web 2.

The method further includes providing an elastomeric film ribbon web 7under tension. The ribbon web 7 has a cross-direction width 8 suitableto provide the desired functionality, such as, for example, about 2.5centimeters, about 2 centimeters, or about 1 centimeter. Examples ofelastomeric films suitable for use as either an elastomeric film webcore layer 5 a or as the elastomeric film ribbon web 7 are disclosed inU.S. Patent Application Publications 2008/0076315, 2008/0095978, and2009/0197041, each of which is assigned to Kimberly-Clark Worldwide,Inc. and each of which is incorporated by reference herein to the extentnot inconsistent herewith. In particular embodiments, it may bedesirable to produce an elastomeric film “off line” for one or both ofthe core layer 5 a and the ribbon layer 7, such that the film can becollected, such as via a roll or spool, and delivered to and unwoundinto the manufacturing process for the personal care article inquestion. Examples of suitable films are disclosed in U.S. PatentApplication Publications 2008/0076315, 2008/0095978, and 2009/0197041.It has been discovered that certain films, such as films based upon someof those disclosed in the preceding publications, can be wound into rollform by taking measures to limit the surface tack of the film. Forexample, in certain embodiments, a film is created which includes acentral layer substantially devoid of inorganic matter, sandwiched byone or two film skin layers, one or both of which include inorganicmatter. In a particular example, a film layer suitable for use inconjunction with the present invention includes a central layercomprised of 100% VISTAMAXX™ propylene polymer from ExxonMobil ChemicalCo. of Houston, Tex., sandwiched on one or both of its faces by a skinlayer(s), the skin layer being comprised of 30% VISTAMAXX™ propylenepolymer and 70% inorganic material, such as calcium carbonate (CaCO₃).Such an exemplary construction allows the film layer to be collectedinto roll form, and subsequently unwound into a laminate manufacturingprocess without undesirable binding of the layers on the roll, and stillthermally fused to other layers of the laminate, as shall be describedbelow.

The method further includes sandwiching the core layer of elastomericmaterial 5 between the first nonwoven web 1 and the second nonwoven web2, and also sandwiching the elastomeric film ribbon web 7 between thefirst nonwoven web 1 and the second nonwoven web 2. In certainembodiments, such as that shown in FIG. 1, the core layer 5 ispositioned in a side-by-side relationship with the ribbon web 7, suchthat the two are not superposed over one another. In other embodiments,such as that shown in FIGS. 2-4, the core layer 5 is superposed over theribbon web 7, such that the ribbon web 7 is partially or entirelyoverlapped by the core layer 5. For example, in an embodiment where thecore layer 5 is an elastomeric film web core layer 5 a, the elastomericfilm web core layer 5 a may not be superposed over the elastomeric filmribbon layer 7 as representatively illustrated in FIG. 1, or,alternatively, the elastomeric film web core layer 5 a may be superposedover the elastomeric film ribbon layer 7 as representatively illustratedin FIGS. 2-4. In one embodiment, the elastomeric ribbon web 7 comprisesa folded-over, integrally formed portion of the elastomeric film webcore layer 5 a (not shown). The basis weights of the film web core layer5 a and the film ribbon web 7 can vary depending on the functionalelastic properties desired in the personal care article. In one example,the basis weights of the film web core layer 5 a and the film ribbon web7 are the same. In another example, they differ by at least 10%, andpreferably by at least 20%.

The method in particular embodiments further includes bonding the corelayer of elastomeric material 5 to at least one of the first nonwovenweb 1 and the second nonwoven web 2. In particular embodiments, such asthat representatively illustrated in FIGS. 1, 2, and 4, the processincludes bonding the core layer 5 a to both the first nonwoven web 1 andthe second nonwoven web, such as in embodiments in which the core layeris an elastomeric film core layer 5 a. In other embodiments, the corelayer 5 a is “pre-bonded” to one of the nonwoven webs, such as the firstnonwoven web 1, in a precursor procedure. If the material is supplied insuch manner (that is, supplied to the personal care articlemanufacturing process in a “half laminate” roll form in which one sideof the film core layer has already been at least provisionally matedwith a nonwoven web, but wherein the opposite side of the film corelayer has not yet been mated with a nonwoven web, and remains exposed),then the process can include bonding the core layer 5 a to just one ofthe first and second nonwoven webs 1, 2.

The method in particular embodiments further includes bonding theelastomeric film ribbon web 7 to the first and second nonwoven webs 1, 2by fusing the elastomeric film ribbon web to the first and secondnonwoven webs, such as via the use of heat, pressure, and/or ultrasonicenergy. In one example, a heated, patterned embossing roll is used toperform the fusing. Desirably, the nature of the film allows it to bebonded to the nonwoven webs without the use of adhesive, but merely viathe introduction of energy such as heat, pressure, or ultrasonic energy.Accordingly, in particular embodiments, the elastomeric film ribbon web7 is bonded to the first and second nonwoven webs 1, 2 solely by fusing,without the use of adhesive Examples of such techniques are taught inU.S. Patent Application Publications 2008/0076315, 2008/0095978, and US2009/0197041, referenced above. In particular embodiments, the filmribbon web 7 can be directly fused to one or both of the first andsecond nonwoven webs 1/2, such as representatively illustrated inFIG. 1. Alternatively, the film ribbon web 7 can be directly fused toone of the nonwoven webs, and indirectly fused to the other nonwoven webby way of being directly and intermediately fused to the core layer 5 orto another layer, such as representatively illustrated in theembodiments of FIGS. 2-4.

If the core layer of elastomeric material 5 is an elastomeric film webcore layer 5 a, in particular embodiments, bonding the core layer ofelastomeric material to at least one of the first and second nonwovenwebs 1, 2 includes fusing the elastomeric film web core layer to atleast one of the first and second nonwoven webs 1, 2. In one example, aheated, patterned embossing roll is used to perform the fusing. Inparticular embodiments, the elastomeric film web core layer 5 a isbonded to at least one of the first and second nonwoven webs solely byfusing, without the use of adhesive. Examples of such techniques aretaught in U.S. Patent Application Publications 2008/0076315,2008/0095978, and US 2009/0197041, referenced above. For example, inparticular embodiments, the method includes fusing the elastomeric filmweb core layer 5 a to one or both of the first and second nonwoven webs1,2 using heat, pressure, and/or ultrasonic energy. In one desirableembodiment, both the elastomeric film web core layer 5 a and theelastomeric film ribbon web 7 are fused, either directly or indirectly,to the first nonwoven web 1 and the second nonwoven web 2 without theuse of adhesive, such as via the use of heat, pressure, and/orultrasonic energy. Using such a technique can in particular embodimentsresult in certain benefits. First, eliminating the conventional use ofadhesive to bond the layers within the elastomeric laminate reducesmaterial cost. Second, eliminating the conventional use of adhesivereduces the cost, maintenance, and delay associated with adhesiveapplication equipment. Finally, if the material used to form theelastomeric film web core layer 5 a is the same as, or is chemicallycompatible with, the material used to form the nonwoven webs materials1,2, waste or scrap from the entire resulting laminate can be recycledand reused to make new nonwoven webs, new elastomeric film webs, orother materials. In a particular example, the elastomeric film web corelayer 5 and the elastomeric film ribbon web 7 are comprised primarily(but not necessarily entirely) of polypropylene, and the nonwoven webs1, 2 are also comprised primarily (but not necessarily entirely) ofpolypropylene. Desirably (but optionally), both the elastomeric film webcore layer 5 a and the elastomeric film ribbon web 7 are fused, eitherdirectly or indirectly, to the first nonwoven web 1 and the secondnonwoven web 2 without the use of adhesive in a single operation.

In another aspect, the present invention pertains to a method 30 ofmanufacturing a plurality of disposable absorbent garments 32; examplesof the method are representatively illustrated in FIGS. 5-8. The method30 builds on the method 10 of forming an elastomeric laminate havingtargeted elastic properties described above. In particular embodiments,the method 30 comprises providing a first nonwoven web 1, such as anouter cover web 1 a, traveling in a machine direction 20. The outercover web 1 a in particular embodiments defines a front edge 26 and aback edge 28, both of which extend in the machine direction 20.

The method 30 in particular embodiments further includes providing atleast one second nonwoven web 2, such as a pair of nonwoven liner webs 2a, 2 b. The method 30 further includes providing at least one core layerof elastomeric material 5 under tension, such as a first core layer 5 aand second core layer 5 b. Each core layer 5 a, 5 b has across-direction width at least 75% that of the width of at least one ofthe first nonwoven web 1 a and the corresponding second nonwoven webs 2a, 2 b. In the examples of FIGS. 5-8, the core layers 5 a, 5 b each havea width that approaches 100% that of the width of each of the respectivesecond nonwoven liner webs 2 a, 2 b. The method further includessandwiching each core layer of elastomeric material 5 a, 5 b between theouter cover web 1 a and the respective nonwoven liner web or webs 2 a, 2b. The method further includes bonding the core layer of elastomericmaterial 5 to the first nonwoven web 1, to the second nonwoven web(s) 2,or to both, such as via fusing as described above. In particularembodiments, the outer cover web 1 a may be provided by two separateouter cover webs, as in the example of FIG. 7. Such an embodimenttherefore includes a pair of first nonwoven webs 1 b, 1 c, a pair ofsecond nonwoven webs 2 a, 2 b, and a pair of core layers 5 a, 5 b.

As described above, in particular embodiments, such as thatrepresentatively illustrated in FIGS. 6 and 7, the process includesbonding (for example, by fusing) the core layer 5 a to both the firstnonwoven web 1 a/1 b and the second nonwoven web 2 a/2 b, such as inembodiments in which the core layer is an elastomeric film core layer 5a/5 b. In these embodiments, each core layer 5 and each nonwoven web 2is separately provided, and they are laminated together during thecontinuous machine manufacture of the garments. For example, asrepresentatively illustrated in FIGS. 6 and 7, in one embodiment themethod includes providing a roll supply of elastomeric film web corelayer 5 a/5 b and providing a separate roll supply of nonwoven webs 2 a,2 b. In other embodiments, the core layer 5 a/5 b is “pre-bonded” to oneof the nonwoven webs, such as a second nonwoven web 2, in a precursorprocedure. If the material is supplied in such manner (that is, suppliedto the personal care article manufacturing process in a “half laminate”roll form in which one side of the film core layer has already beenmated with a nonwoven web, but wherein the opposite side of the filmcore layer has not yet been mated with a nonwoven web, and remainsexposed), then the process includes bonding the core layer 5 a to thefirst nonwoven web 1, the second nonwoven web 2, or both. For example,as representatively illustrated in FIGS. 5 and 8, the method can includeproviding a single roll supply of elastomeric film laminate 15 (shown inthe example as two separate supplies of film laminate 15 a and 15 b),wherein the laminate 15 on the roll supply(ies) comprises at least twolayers, one layer being an elastomeric film web core layer 5 a/5 b andthe other layer being a nonwoven layer 2 a/2 b, to provide a pre-made,“one-sided” elastomeric laminate 15 a/15 b. Note that in FIGS. 15 and18, individual layers of the elastomeric film laminate 15 are notdepicted, but instead the laminate is depicted as a single, “pre-made”laminate substrate.

In the embodiments of FIGS. 5-8, the outer cover web 1 a (and in thecase of FIG. 7, web 1 b), the nonwoven webs 2 a, 2 b, and the corelayers of elastomeric material 5 a, 5 b collectively define a compositegarment web 110. (Note that in the example of FIG. 7, the compositegarment web 110 is defined by two composite garment web portions 110 aand 110 b.) The method 30 in particular embodiments further includesproviding a supply 158 of individual absorbent assemblies 58,superposing individual absorbent assemblies 58 over the compositegarment web 110, and attaching the individual absorbent assemblies 58 tothe composite garment web 110. In certain embodiments, such as thoserepresentatively illustrated in FIGS. 5-8, the absorbent assemblies maybe manufactured in one orientation, and then cut and rotated 90 degrees(such as at cut-and-rotate station 159) before attachment to thecomposite garment web 110. The method can in particular embodimentsfurther include removing portions 105 of the composite garment web 110(such as at cutting station 108) to define a series of spaced apartholes 106, thereby defining in the composite garment web 110 aninterconnected series 120 of disposable absorbent garments 32. Suchportions 105 can be removed from the outer cover web 1 a before thenonwoven webs 2 a, 2 b and the core layers 5 a, 5 b are attached to theouter cover web 1 a (not shown), or can be removed from the outer coverweb 1 a after the nonwoven webs 2 a, 2 b and the core layer 5 a, 5 b areattached to the outer cover web 1 a (as representatively illustrated inFIGS. 5-8). Furthermore, such portions 105 can be removed from thecomposite garment web 110 before the individual absorbent assemblies 58are attached to the composite garment web 110 (as representativelyillustrated in FIGS. 5-8), or can be removed from the composite garmentweb 110 after the individual absorbent assemblies 58 are attached to thecomposite garment web (not shown).

The method 30 can further include folding the composite garment web 110,such as at a garment folding station 112, along a transversely centeredlongitudinal fold line that extends in the machine direction 20, suchthat the front edge 26 is brought into close proximity with the backedge 28. In particular embodiments, the method further comprisescreating a series of side seam bonds 150 (such as at seaming station152) spaced apart in the machine direction 20. The method additionallycomprises cutting the composite garment web 110 at a series of cutlocations 155 (such as at cutting station 156) spaced apart in themachine direction 20 to create the plurality of disposable absorbentgarments.

The method 30 further includes providing at least one elastomeric filmribbon web 7 under tension, sandwiching the elastomeric film ribbon web7 between two nonwoven web layers, such as the first nonwoven web 1 aand the second nonwoven web or webs 2 a, 2 b, and bonding via fusing,directly or indirectly (as explained above), the elastomeric film ribbonweb 7 to the first and second nonwoven webs 1, 2, preferably without theuse of adhesive. When donned, the personal care garment defines a waistopening 40 and two leg openings 42. In particular embodiments, theelastomeric film ribbon web 7 is positioned adjacent the waist opening40, the front edge of a leg opening 42, and/or the back edge of a legopening 42. For example, in particular embodiments, the method 30includes attaching a continuous back leg elastic ribbon web 7 a to theouter cover web 1 a/1 b or to one of the nonwoven liner webs 2 a, 2 b.The back leg elastic ribbon web 7 a extends or travels predominantly inthe machine direction 20. In particular embodiments, as representativelyillustrated in FIGS. 5-8, the method further comprises partially orentirely overlapping the back leg elastic ribbon web 7 a with the corelayer 5. For example, the method may comprise sandwiching at least aportion of the continuous back leg elastic ribbon web 7 a between thecore layer 5 and the outer cover web 1 (FIGS. 5, 6, and 8), or betweenthe core layer 5 and the nonwoven web or webs 2 (FIG. 7). Similarly, inparticular embodiments, the method 30 also includes attaching acontinuous front leg elastic ribbon web 7 b to the outer cover web 1 a/1b or to one of the nonwoven liner webs 2 a, 2 b. The front leg elasticmember 7 b extends or travels predominantly in the machine direction 20.In particular embodiments, as representatively illustrated in FIGS. 5-8,the method further comprises partially or entirely overlapping the frontleg elastic ribbon web 7 b with the core layer 5. For example, themethod may comprise sandwiching at least a portion of the continuousfront leg elastic ribbon web 7 b between the core layer 5 and the outercover web 1 (FIGS. 5, 6, and 8), or between the core layer 5 and thenonwoven web or webs 2 (FIG. 7).

In particular embodiments, the method 30 also can include sandwichingcontinuous waist elastic ribbon webs 7 c and 7 d between the outer coverweb(s) 1 a/1 b and the nonwoven liner webs 2 a, 2 b. In one embodiment,a waist elastic ribbon web 7 is sandwiched in a straight line, and a legelastic ribbon web is sandwich in an oscillating curved line (see, forexample, FIG. 4). In one variant, such as that representativelyillustrated in FIG. 8, the method can include folding the edge of one orboth of first nonwoven web 1 a or the second nonwoven web or webs 2 a, 2b. For example, in one embodiment, the method includes folding the frontedge 26 of the outer cover web 1 a, such as at a front waistband foldingstation 136, to create a front waist edge fold 127 and to sandwich theribbon web 7 d within the fold. In such an embodiment, the secondnonwoven web 2 d comprises an integrally formed, folded-over portion ofthe first nonwoven web 1 a. The method may instead or additionallyinclude folding the edge 128 of the outer cover web 1 a, such as at aback waistband folding station 138, to create a back waist edge fold 129and to sandwich the ribbon web 7 c within the fold. In such anembodiment, the second nonwoven web 2 c comprises an integrally formed,folded-over portion of the first nonwoven web 1 a.

In certain embodiments, the method 30 further comprises at leastpartially deactivating the elastomeric properties of one or more of thecore layers 5, of one or more of the ribbon webs 7, or both, using heat,ultrasonics, pressure, or other techniques. In particular embodiments,portions of both a core layer 5 and a ribbon web 7 are deactivated in asingle process step, such as via a single rotary deactivating or“deadening” device. Examples of techniques to deaden or deactivateelastic properties in various elastomeric laminates are disclosed inU.S. Pat. No. 5,660,657 issued May 5, 1998 to Rajala et al. and assignedto Kimberly-Clark Worldwide, Inc., and also disclosed in U.S.application Ser. No. 12/605,092.

In particular embodiments, various components, such as the outer coverweb 1 a, the liner webs 2 a, 2 b, the core webs 5 a, 5 b, or the ribbonwebs 7 a, 7 b, 7 c, 7 d can be printed or pigmented to include graphics,text, color, or other images. Such printing can occur during assembly ofthe garment in conjunction with the presently disclosed method, or canoccur prior to such assembly in an off-line, “pre-preprinting” orpigmenting step.

It will be appreciated that details of the foregoing embodiments, givenfor purposes of illustration, are not to be construed as limiting thescope of this invention. Although only a few exemplary embodiments ofthis invention have been described in detail, those skilled in the artwill readily appreciate that many modifications are possible in theexemplary embodiments without materially departing from the novelteachings and advantages of this invention. Accordingly, all suchmodifications are intended to be included within the scope of thisinvention, which is defined in the following claims and all equivalentsthereto. Further, it is recognized that many embodiments may beconceived that do not achieve all of the advantages of some embodiments,particularly of the preferred embodiments, yet the absence of aparticular advantage shall not be construed to necessarily mean thatsuch an embodiment is outside the scope of the present invention.

We claim:
 1. A method of forming an elastomeric laminate having targetedelastic properties for use in personal care articles, the methoddefining a machine direction and a cross-machine direction, the methodcomprising: providing first and second nonwoven webs, each defining across-direction width; providing a core layer of elastomeric materialunder tension, the core layer having a cross-direction width at least75% that of the width of at least one of the first and second nonwovenwebs, wherein the core layer of elastomeric material is an elastomericfilm web core layer; folding over an integrally formed portion of theelastomeric film web core layer to provide an elastomeric film ribbonweb; sandwiching the core layer of elastomeric material and theelastomeric film ribbon web between the first and second nonwoven webs;bonding the core layer of elastomeric material to at least one of thefirst and second nonwoven webs; and bonding the elastomeric film ribbonweb to the first and second nonwoven webs by directly or indirectlyfusing the elastomeric film ribbon web to the first and second nonwovenwebs.
 2. A method of manufacturing a personal care garment, the garmentcomprising an elastomeric laminate having targeted elastic properties,the method defining a machine direction and a cross-machine direction,the method comprising: providing first and second nonwoven webs, eachdefining a cross-direction width; providing a core layer of elastomericmaterial under tension, the core layer having a cross-direction width atleast 75% that of the width of at least one of the first and secondnonwoven webs, wherein the core layer of elastomeric material is anelastomeric film web core layer; folding over an integrally formedportion of the elastomeric film web core layer to provide an elastomericfilm ribbon web; sandwiching the core layer of elastomeric material andthe elastomeric film ribbon web between the first and second nonwovenwebs; bonding the core layer of elastomeric material to at least one ofthe first and second nonwoven webs; and bonding the elastomeric filmribbon web to the first and second nonwoven webs by directly orindirectly fusing the elastomeric film ribbon web to the first andsecond nonwoven webs, wherein when donned, the personal care garmentdefines a waist opening and two leg openings, and wherein theelastomeric film ribbon web is positioned adjacent at least one of thewaist opening and the two leg openings.